Structural polymer core assembly, method of manufacture and method of use

• US 20080135167A1
• Filed: 10/05/2007
• Published: 06/12/2008
• Est. Priority Date: 01/28/2002
• Status: Active Grant

• Current Assignee: Innovative Composites, Inc. (Innovative Composites International, Inc.)
• Original Assignee: Eleison Composites L L C (Eleison Composites)
• Inventors: Stoll, John R., Panik, Keith, Simmons, Richard A., Simmons, F. Arthur
• Granted Patent: US 7,857,934 B2
• Time in Patent Office: Days
• US Class Current: 156/245
• CPC Class Codes: B32B 3/28 characterised by a layer comprising a deformed thin sheet , i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled B32B29/08 takes precedence
• CPC Class Codes: Y10T 156/1039 Surface deformation only of sandwich or lamina [e.g., embossed panels]
• CPC Class Codes: Y10T 428/24322 Composite web or sheet
• CPC Class Codes: Y10T 428/24331 including nonapertured component
• CPC Class Codes: Y10T 428/24661 Forming, or cooperating to form cells
• CPC Class Codes: Y10T 428/24678 Waffle-form
• CPC Class Codes: Y10T 428/24694 Parallel corrugations

Abstract

A composite structure, and method of manufacturing it, having a specified width, length, and height defining a top and bottom the composite structure. The composite structure includes a three dimensional structural core constructed of a polymer with a first series of a geometric pattern repeated along its length. The structural core also has a second series of the geometric pattern repeated along the width thereof. The geometric patter may be a sinusoidal curve or a substantially pyramidal shape. The composite structure also includes a first reinforcement layer made of a polymer positioned above the structural core and bonded thereto. It also includes a second reinforcement layer made of a polymer that is positioned below the structural core and bonded thereto. The composite structure may also include a decorative layer above the first reinforcement layer, an acoustical batting layer positioned between the first reinforcement layer and the structural core, and may include fire retardant chemicals.

Claims

1-17. -17. (canceled)

18. A method of utilizing a thermoformable composite structure having a specified width, length, and height defining a top and bottom of said composite structure comprising:

providing a single thermoformable three dimensional structural core constructed of a fiber infused thermoplastic with a pyramidal geometric pattern repeated along the length thereof, said pyramidal geometric pattern repeated along the width thereof;

forming said pyramidal geometric pattern so that it is symmetric about a neutral axis of said structural core and is comprised of a plurality of pyramidal shapes;

forming each of said pyramidal shapes to have four side faces which intersect to form edges;

forming each of said edges to include a radius;

forming said pyramidal geometric pattern to have a series of peaks and troughs that have flat bottoms and tops;

thermally bonding a thermoformable first reinforcement layer to the top of said structural core wherein said first reinforcement layer is constructed of the same fiber infused thermoplastic as said structural core; and

thermally bonding a thermoformable second reinforcement layer to the bottom of said structural core wherein said second reinforcement layer is constructed of the same fiber infused thermoplastic as said structural core.

20. The method of claim 18 further comprising:

using said composite structure as a component of an automotive interior.

21. The method of claim 18 further comprising:

using said composite structure as a load bearing portion of a stationary structure.

22. The method of claim 18 further comprising:

using said composite structure as a door.

23. The method of claim 18 further comprising:

using said composite structure to construct at least a portion of a marine vehicle.

24. The method of claim 18 further comprising:

using said composite structure as a component of an aircraft interior.

25. The method of claim 18 further comprising:

using said composite structure as a cooking sheet.

26. The method of claim 18 further comprising:

treating at least a portion of said composite structure with fire retardant chemicals.

27. The method of claim 26 further comprising:

using said composite structure as a component of a piece of furniture.

28. The method of claim 18 further comprising:

placing a layer of acoustical batting between said structural core and said first reinforcement layer.

29. The method of claim 28 further comprising:

using said composite structure as a sound absorption panel.

30. The method of claim 29 wherein at least one of said first and second reinforcing layers contains repeated openings along the length and width thereof.

19. (canceled)

31-42. -42. (canceled)

43. A method of manufacturing a structural composite for use in the interior of a vehicle comprising:

providing a sheet of a fiber infused thermoplastic;

preheating said sheet of fiber infused thermoplastic;

forming said sheet into a single thermoformable structural core with a pyramidal geometric pattern repeated along the length thereof and said pyramidal geometric pattern repeated along the width thereof by way of compression;

forming said pyramidal geometric pattern so that it is symmetric about a neutral axis of said structural core and is comprised of a plurality of pyramidal shapes;

forming each of said pyramidal shapes to have four side faces which intersect to form edges;

forming each of said edges to include a radius;

forming said pyramidal geometric pattern to have a series of peaks and troughs that have flat bottoms and tops;

laminating a thermoformable first reinforcement layer constructed of the same fiber infused thermoplastic as said structural core onto the top of said structural core;

laminating a thermoformable second reinforcement layer constructed of the same fiber infused thermoplastic as said structural core onto the bottom of said structural core;

affixing a decorative layer to the outer portion of said first reinforcement layer; and

forming said structural composite into the shape for which it will be used in said interior of said vehicle.

44. The method of claim 43 further comprising:

positioning a layer of acoustical batting between said structural core and one of said first and second reinforcement layers.

45. The method of claim 43 further comprising:

designing said pyramidal geometric pattern with the assistance of a computer to have specific mechanical properties.

46. (canceled)

47. A method of continuously manufacturing a structural composite comprising:

providing a sheet of polymer;

preheating said sheet of polymer;

providing a forming apparatus comprised of two opposing portions;

each opposing portion having raised areas which intermesh when said two opposing portions are brought together;

continuously feeding said preheated sheet of polymer into said forming apparatus and forming said sheet into a structural core with a geometric pattern repeated along the length and width thereof;

laminating a first reinforcement layer constructed of a polymer onto the top of said structural core;

laminating a second reinforcement layer constructed of a polymer onto the bottom of said structural core.

48. The method of claim 47 further comprising:

positioning a layer of acoustical batting between said structural core and one of said first and second reinforcement layers.

49. The method of claim 47 further comprising:

designing said geometric pattern with the assistance of a computer to have specific mechanical properties.

50. The method of claim 47 wherein said sheet of polymer is infused with fibrous material.

51. The method of claim 47 wherein said geometric pattern is pyramidal.

52. A method of continuously manufacturing a structural composite comprising:

providing a sheet of polymer;

preheating said sheet of polymer;

providing a forming apparatus comprised of an array of raised areas situated on a single, one-sided stationary or moving surface;

continuously feeding said preheated sheet of polymer onto said forming apparatus and forming said sheet into a structural core with a geometric pattern repeated along the length and width thereof by way of vacuum or other assisted molding;

laminating a first reinforcement layer constructed of a polymer onto the top of said structural core;

laminating a second reinforcement layer constructed of a polymer onto the bottom of said structural core.